Unique cardboard box container for replacing wood pallets

ABSTRACT

A unique cardboard box container for replacing wood pallets is disclosed. In its unfolded, flattened form the cardboard box comprises a central rectangular panel with two contiguous side panels and two end tabs contiguous to the two ends of the central rectangular panel. The side panels have creases extending the length of the side panels for folding the side panels over a boxed strip or panel product placed on the central rectangular panel. The two end tabs are also creased enabling the end tabs to be folded over the ends of a layer of boxed strip or panel product placed over the folded side panels, which overlay the boxed strip or panel product placed on the central rectangular panel. Two cardboard box containers are aligned in parallel to form two stringers and a layer of boxed strip or panel products is placed on the stringers with the end tabs of the two cardboard box containers folded over the ends of the layer. The ends of the overlapping end tabs are fastened together to form a unitized platform base on which additional layers of boxed strip or panel products can be placed for transporting or shipping.

FIELD OF INVENTION

This invention relates to a cardboard container package design wherebystrip or panel type products can be shipped or transported withoutrequiring the use of wood pallets as carriers for the products. Examplesof products for which this invention is useful are boxed cedar closetlinings, boxed hardwood or laminated strip flooring, and shelvingproducts including fireplace mantels.

BACKGROUND

In shipping strip or panel type products, it is standard practice to usepallets made of wood or other materials (e.g. gypsum board strips orplastic foams) as carriers for the strip or panel type products. Whenthese pallets are used for shipping products, the products are usuallystacked on the pallets and the pallets carrying the products are movedto and from storage to transporting vehicles using forklift trucks. Thereceiving facility, retail store or factory, has to deal with disposingthe pallets. In some cases, the receiving facility collects and storesthe pallets for return to the manufacturer of the strip or panel typeproducts.

U.S. Pat. No. 5,174,448 discloses a cardboard container for stackingglass sheets which is carried on a reusable wood pallet. Thisillustrates the standard method for shipping product carried by areusable wood pallet.

U.S. Pat. No. 5,141,109 discloses using strips of scrap gypsum board toform pedestals to support a shipping container above the ground or floorwhereby a forklift truck can be used to move the container. The patentalso shows shipping bands, straps, ribbons, tapes, cords or wires, whichsurround the container and the pedestals.

U.S. Pat. No. 3,855,756 discloses sub-unitized containers carried on awood pallet with a heat-shrunk enveloping material holding thecontainers as an integral container on the pallet.

It is an object of this invention to provide a cardboard box containerfor shipping or transporting strip or panel type products whereby theuse of wood pallets can be eliminated.

It is another object of this invention to provide a container to enclosea box containing the strip or panel product to form stringers which actas a base separating the bottom layer of boxed strip or panel productsfrom the floor or ground whereby a forklift truck can be used totransport stacked, boxed product.

It is a further object of this invention to provide a method forstacking boxed, strip or panel products in a unitized form whereby theneed for a wood pallet base is eliminated.

The objects and advantages of this invention will be readily understoodfrom a consideration of the drawings and the following detaileddescription of the preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

In the description of the preferred embodiments of the inventionpresented below, reference is made to the accompanying drawings inwhich:

FIG. 1 is a top plan view of the cardboard box container of thisinvention showing creases in the flat container.

FIG. 2 is a top plan view of the cardboard box container of thisinvention showing a boxed strip product in dashed lines placed on thecentral panel of the container.

FIG. 3 is a perspective view of two cardboard box containers of thisinvention each enclosing a boxed strip product and aligned to form twostringers and showing a layer of boxed strip product in dashed linesoverlaying a side panel of the two cardboard box containers forming thestringers and at right angles to the stringers.

FIG. 4 is a perspective view of two cardboard box containers of thisinvention each enclosing a boxed strip product and aligned to form twostringers and a layer of boxed strip product in dashed lines overlayingthe stringers with the end tabs of the two cardboard box containersfolded over the ends of the layer of boxed strip product.

FIG. 5 is a perspective view of the assembly shown in FIG. 4 with alayer of boxed strip product in dashed lines overlaying the FIG. 4assembly at right angles thereto.

DESCRIPTION OF PREFERRED EMBODIMENTS

This invention relates to a cardboard container that can be shaped intoa secondary box, which can be used to replace wooden pallets forshipping or transporting boxed strip or panel type products. Thecardboard container has a unique design whereby it can be folded overboxed strip or panel products to form stringers which separate a baselayer of boxed strip or panel type product from the floor or groundenabling a forklift truck to slide its blades under a stack of boxedproduct layers placed on top of the base layer of boxed strip or paneltype products.

The cardboard container of this invention is useful for shipping ortransporting strip or panel type products, especially those productsthat are shipped as individual pieces in boxes. Of course, more than onepiece of product may be contained in a box. The containers of thisinvention are useful in shipping hardwood or laminated strip flooringmaterials. They are useful in shipping boxed closet linings such ascedar closet linings. The containers are also useful in shippingshelving products and fireplace mantels.

The advantages provided by the cardboard containers of this inventionare cost savings, with the cost of the cardboard containers beingsubstantially less than the cost of wood pallets and reduced freightcosts by eliminating the weight of wood pallets. Furthermore, thereceiving retail store or factory would not have to deal with storageand/or disposal of the wood pallets. The cardboard containers of thisinvention can be disposed of with other cardboard, which is normallysold to a paper recycling company. An additional benefit would beconserving the timber natural resource required to make the woodpallets.

For a description of a preferred embodiment of the invention, referenceis made to the drawings, which illustrate a cardboard container inaccordance with the invention.

FIG. 1 illustrates a cardboard box container (10) in its unfolded form.The container (10) comprises a central rectangular panel (11) sized toreceive a boxed strip or panel product. Contiguous to the centralrectangular panel (11) and of substantially equal length thereto are twoside panels (12) and (13) both of which are creased, with the creases(14) and (15) extending the length of the side panels and being locatedat a distance from the side edges of the central rectangular panel (11)substantially equal to the height of the boxed strip or panel productwhich is to be placed on the central rectangular panel (11) and enclosedby folding the side panels (12) and (13) over the boxed strip or panelproduct. The width of the side panels (12) and (13) from the creases(14) and (15) to the outer edges (16) and (17) of the side panels (12)and (13) respectively is preferably, substantially the width of thecentral rectangular panel (11). However, it is only necessary that thewidth of the side panels (12) and (13) be sufficient that the sidepanels overlap when they are folded over the boxed strip or panelproduct placed on the central rectangular panel (11). It is within thescope of the invention that the side panels (12) and (13) do not overlapwhen folded over the boxed strip or panel product.

In addition to side panels (12) and (13), the cardboard box container(10) has end tabs (18) and (19) contiguous to the two ends of thecentral rectangular panel (11). Both end tabs (18) and (19) are creased,with the creases (20) and (21) being located at a distance from the endedges of the central rectangular panel (11) substantially equal to twicethe height of the boxed strip or panel product which is to be placed onthe central rectangular panel (11) and enclosed by folding the sidepanels (12) and (13) over the boxed strip or panel product.

Referring now to FIG. 2, the same cardboard box container (10) as shownin FIG. 1 is illustrated in FIG. 2, using the same numerals as inFIG. 1. Also shown in FIG. 2 is a boxed strip product (22) in dashedlines placed on the central panel (11) of the container (10). Inaddition, the side panels (12) and (13) are shown as slightly foldedabout the creases (14) and (15) respectively. As shown in FIG. 2, theboxed strip product (22) overlays the entire central panel (11) of thecontainer (10).

FIG. 3 illustrates two cardboard box containers of this invention eachenclosing a boxed strip product (22) and aligned to form two stringers(23) and (23′). Each stringer comprises the cardboard box container withthe side panels folded over and enclosing the boxed strip product (22).A layer (24) of boxed strip product is shown in dashed lines overlayingside panels (12) and (13) of the two cardboard box containers formingstringers (23) and (23′). Layer (24) of boxed strip product overlays thestringers (23) and (23′) at right angles thereto. As shown in FIGS. 3and 4, end tabs (18) and (19) are subsequently folded over the ends oflayer (24) of boxed strip product to form a platform base upon whichfurther layers of boxed strip product may be placed.

As clearly shown in FIG. 4, the length of the end tabs (18) and (19)measured from the creases (20) and (21) to the ends (25) of the end tabsis greater than one half the length of the central rectangular panel(11) whereby the end tabs (18) and (19) overlap when folded over theends of layer (24). The overlapping tabs (18) and (19) are fastenedtogether with adhesive, mechanical fasteners such as heavy staples orinterlocking the tabs with slots made in each tab. This unitizes thestringers (23) and (23′) and fastens and secures the stringers (23) and(23′) to the layer (24) of boxed strip product. The unitized stringers(23) and (23′) secured to the layer (24) form a platform base upon whichfurther layers of boxed strip product can be placed.

FIG. 5 illustrates the placement of an additional layer (26) of boxedstrip product on the platform base shown in FIG. 4. As shown in FIG. 5,it is preferred to place each additional layer of boxed strip product atright angles to the layer beneath it for greater stability. However,placement of the layers at right angles for alternate layers is notcritical. The entire stack of boxed strip product is unitized by bandingthe layers together or by applying stretch wrap or heat shrink wrap tothe perimeter of the layers for stability of the layers during shippingor transporting.

This invention has been described in detail, with particular referenceto preferred embodiments, but it should be appreciated that variationsand modifications can be effected within the scope of the invention.

1. A cardboard box container for replacing wood pallets which in itsunfolded, flattened form comprises a central rectangular panel; two sidepanels contiguous to the central rectangular panel, both of said sidepanels having creases extending the length of the side panels and beinglocated at a distance from the side edges of the central rectangularpanel substantially equal to the height of a boxed strip or panelproduct which is to be placed on the central rectangular panel; and twoend tabs contiguous to the two ends of the central rectangular panel,both of said end tabs being creased, with the creases located at adistance from the end edges of the central rectangular panelsubstantially equal to twice the height of the boxed strip or panelproduct which is to be placed on the central rectangular panel.
 2. Thecardboard box of claim 1 in which the length of the two side panels issubstantially equal to the length of said central rectangular panel. 3.The cardboard box of claim 1 in which the width of the side panels issufficient that the side panels overlap when they are folded over theboxed strip or panel product placed on the central rectangular panel. 4.The cardboard box of claim 1 in which the length of the end tabsmeasured from the creases to the ends of the end tabs is greater thanone half the length of the central rectangular panel.
 5. The cardboardbox of claim 2 in which the width of the side panels is sufficient thatthe side panels overlap when they are folded over the boxed strip orpanel product placed on the central rectangular panel.
 6. The cardboardbox of claim 2 in which the length of the end tabs measured from thecreases to the ends of the end tabs is greater than one half the lengthof the central rectangular panel.
 7. The cardboard box of claim 3 inwhich the length of the end tabs measured from the creases to the endsof the end tabs is greater than one half the length of the centralrectangular panel.
 8. The cardboard box of claim 1 in which a boxedstrip or panel product is placed on the central rectangular panel andboth side panels are folded over said boxed strip or panel product. 9.The cardboard box of claim 8 in which the length of the two side panelsis substantially equal to the length of said central rectangular panel.10. The cardboard box of claim 9 in which the width of the side panelsis sufficient that the side panels overlap.
 11. A platform basecomprising two cardboard boxes aligned in parallel; each of saidcardboard boxes having a central rectangular panel with a boxed strip orpanel product placed on said central rectangular panel and coveringsubstantially the entire surface of said central rectangular panel; eachof said cardboard boxes having two side panels contiguous to the centralrectangular panel with the side panels of each of said cardboard boxesfolded over and enclosing said boxed strip or panel product; a layer ofboxed strip or panel product overlaying the side panels of both of saidcardboard boxes and placed at right angles to both of said cardboardboxes; each of said cardboard boxes having two end tabs contiguous tothe two ends of the central rectangular panel with both of said end tabson both of said cardboard boxes folded over and enclosing both ends ofsaid layer of boxed strip or panel product; with both of said end tabson both of said cardboard boxes being of sufficient length that theyoverlap when they are folded over the ends of said layer of boxed stripor panel product; and said folded over end tabs on both of saidcardboard boxes being fastened to each other to form a unitizedstructure.
 12. The platform base of claim 11 in which the length of thetwo side panels on each of said cardboard boxes is substantially equalto the length of the central rectangular panel on both cardboard boxes.13. The platform base of claim 11 in which the width of the side panelson both of said cardboard boxes is sufficient that the side panelsoverlap the boxed strip or panel product.
 14. The platform base of claim11 in which the end tabs are fastened by means selected from the groupconsisting of adhesives, mechanical fasteners or slots formed in theends of the tabs.
 15. The platform base of claim 12 in which the endtabs are fastened by means selected from the group consisting ofadhesives, mechanical fasteners or slots formed in the ends of the tabs.16. The platform base of claim 13 in which the end tabs are fastened bymeans selected from the group consisting of adhesives, mechanicalfasteners or slots formed in the ends of the tabs.
 17. The platform baseof claim 13 on which additional layers of boxed strip or panel productsare stacked for transporting or shipping.
 18. The platform base of claim17 in which each additional layer of boxed strip or panel products isplaced at a right angle to the layer beneath it.
 19. The platform baseof claim 17 in which the additional layers of boxed strip or panelproducts is unitized by means selected from a group consisting ofbanding or applying stretch wrap or heat shrink wrap to the perimeter ofthe layers.
 20. The platform base of claim 18 in which the additionallayers of boxed strip or panel products is unitized by means selectedfrom a group consisting of banding or applying stretch wrap or heatshrink wrap to the perimeter of the layers.